Mattress and method of making the same



. 24, 1935. E, L. sxomsmm 2,925,323

MATTRESS AND METHOD OF MAKING THE SAME Filed Sept. 18, 1955fldv'ardzfiroms iery Patented Dec. 24, 1935 UNITED STATES PATET FFIE.

MATTRESS AND METHOD OF MAKFNG THE SAME 1 Claim.

It is an object of this invention to provide a mattress with a novelarrangement of edge rolls and boxing whereby the stitches forming theedge rolls are entirely concealed and the boxing is ren- 5 dered moredurable and neat in appearance.

A particular object is to provide, on the inner surface of the boxing,narrow strips of inexpensive material arranged to be sewed to inner, topand bottom casing members to form corner rolls which are concealedwithin the mattress.

Another object is to provide an improved method of constructing amattress wherein less precision is required in the operation of formingthe edge rolls.

In the manufacture of my improved mattress, a boxing strip of the usualor suitable type has sewed thereto a pair of relatively narrow stripsextending along the upper and lower edges. The free. edges of thesestrips are then secured to top and bottom inner casing sheets, leavingone side open, and then the body of filling material, which preferablyincludes a body of upholstery springs, is inserted in the inner casingand the latter is closed by sewing in the usual manner. As the nextstep, corner rolls are formed by manually stitching through the narrowstrips, filling and top and bottom casing sheets, leaving the boxingproper or main outer boxing strip free to be extended upward inconcealment of the roll stitches. 30 Top and bottom, outer cover membersare now applied, together with suitable top and bottom padding, and themargins of the cover members are sewed directly to the free edges of themain boxing strip while the latter is extended to overlap 35 and concealthe roll stitches. This completes the mattress.

' The invention will be best understood by reference to the accompanyingdrawing in whichz- Figure 1 is a fragmentary, vertical section and partelevation of my improved boxing, inner casing and filling, without thetop and bottom covers, and

Fig. 2 is a similar View showing the outer covers and padding in place.

As shown in the drawing, I provide a main, outer boxing strip 3 upon theinner surface of which is secured a pair of relatively narrow strips 4of fabric. These strips are secured to the boxing strip by lines ofstitches 5 extending parallel to and spaced a substantial distance fromthe upper and lower edges of the boxing. The boxing may be quilted, asshown, with horizontal rows of stitches 6 extending through the innerand outer boxing strips and through suitable felt or other fillingbetween said strips. Attached along seams llla to the free, longitudinaledges of the strips 4 are top and bottom casing sheets I which form Withsaid strips and with the boxing, an inner casing containing suitablestufiing material 8 and a body of springs 9. Corner or edge rolls II]are 5 formed by long stitches l extending through the strips 4, stufiing8 and casing sheets 1 at each corner. It will be understood that thesestitches H are manually applied and are of considerable length,longitudinally of the boxing, so that the 10 exterior of the strips 4and members 1 are indented or formed with depressions of substantialdepth at regular intervals. To conceal these depressions and to give arelatively smooth, unbroken contour to both the boxing and top andbottom of the mattress, I provide top and bottom outer covers I2 andsecure the edges of these covers directly to the free edges of theboxing strip 3. The seams thus formed are covered in the usual manner bytapes l3. Before applying the covers l2, layers of padding M are appliedto the outer surfaces of the sheets I to fill the top and bottomdepressions produced by the stitches II and to give the desirableconvexity to the edge portions of the mattress.

Referring to the elements shown in the drawing, I prefer the followingprocedure in the manufacture of my improved mattress. A boxing strip 3with its quilting has the relatively narrow strips 4 sewed to its innersurface along the lines 5, leaving the strips 4 as free flaps overlyingthe inner surfaces of the boxing. Now the inner casing of the mattressis formed by attaching the top and bottom sheets I to the freelongitudinal edges of the strips 4, along seams Illa, leaving one sideof the mattress open. Now this casing is filled by forcing in thematerial 8 and body of springs 9. The casing is then closed, theoperation of forming the edge rolls H! by means of the stitches H isperformed, the felt or padding I4 is applied to the fabric 1 and theouter covers l2 are secured in place by sewing and applying the tape 13at the junction of the sheets 12 with the outer boxing strip 3.Obviously, the mattress may be tufted in accordance with present commonpractice.

It is important to note that the stitches II forming the corner rolls donot extend to the outer surfaces of either the boxing or the covers I 2so that a substantially smooth, unbroken contour is maintained on allexterior surfaces adjacent to the mattress edges and the stitchesforming the corner rolls are not exposed to wear on the exterior of themattress. At the same time the advantages of rolled corners or edges 55are secured. I prefer to construct the strips 4 from strong, butinexpensive, material which would not be suitable for use on theexterior of the mattress. This. reduces the cost of the mattress and mymethod of manufacture effects a further saving in that the time requiredfor applying the stitches is reduced because less precision is requiredin applying the stitches, as compared with methods where theroll-forming stitches appear on the exterior of the mattress.

By providing the initially separate strips 4 extending only along theupper and lower margins of the main boxing strip, I am enabled toeconomically reinforce the edge rolls where increased strength is neededindependently of the boxing strip which is quilted on its inner surface.Such fragile material is frequently employed on the inner surface of thequilting that it is inadequate to properly hold the long stitches llemployed in forming the corner rolls. This is particularly true whereSwiss embroidery or design strips are employed as the boxing. Suchboxing has rather intricate designs and the inner or backing strips forthe quilting are inadequate for the formation of the edge rolls.

Having described my invention, what I claim 7 as new and desire toprotect by Letters Patent is:

A mattress having in combination a main, outer boxing strip havingquilted padding on its inner surface, a pair of relatively narrow stripsoverlying the inner surface of said boxing strip and. secured theretoalong lines extending parallel, to and spaced from the upper and loweredges of said boxing strip, top and bottom, inner casing sheets unitedto said relatively narrow strips, filling material confined by saidsheets, boxing strip and narrow strips, ties extending through saidnarrow strips, filling and inner casing sheets to form corner rolls andtop and bottom, outer covers secured to the free edges of said mainboxing strip and completely covering the top and bottom respectively ofthe mattress, said boxing strip and covers being ar- 20 ranged toconceal said ties.

EDWARD L. BRONSTIEN.

